Duplex copy printing system and method

Abstract

 A system for generating complete sets of copies after a jam occurs with respect to copy sheets is effected by maintaining count of sheets reaching an exit pocket (43) and retained in a duplex tray (33) for determining therefrom images lost due to the jam and responsive thereto generating replacement copies. For effecting job recovery due to jams occurring during imaging of duplex copies, replacement sheets are generated immediately after each jam to replace sheets lost due to the jam by determining the number of pages to be printed, dividing this number by two, and subtracting therefrom the count of sheets in the duplex tray and in the exit pocket, with this determination being then used to control generation of first side images on sheets needed for replacement purposes with said sheets being then conveyed to the duplex tray so that the resulting duplex copy generation is complete when reaching the exit pocket.

Description

[0001] This invention relates to duplex copy printing systems and methods.

[0002] Copying of material is well known and many diverse systems and methods have heretofore been suggested and used to achieve the desired end. One such system is an electrical-signal-driven printer wherein signals representative of the visual images on each page to be printed are supplied to the printer in numerical page order. If only one side of a recording medium (such as a paper copy sheet, for example) is to have an image printed thereon, each signal may be used when received to print the visual image on sheets as fed through the printer. When multiple copies are desired, however, the electrical signals must be inserted, when received, in some form of a recirculating delay line and the delay line recycled as needed to print the number of copies desired.

[0003] For simplex copies (i.e., copies having an image on one side only), each electrical signal representative of a page to be imaged is brought to a copying, or printing, area where the image is formed on the sheet and the sheet then discharged from the printer.

[0004] For duplex copies, i.e. copies having an image on both sides of the copy sheet, different electrical signals representative of each page must be brought at different times to the printing area and the copy sheet must be brought to the printing area with one side exposed for printing during a first pass and the opposite side exposed for printing during a subsequent second pass. Obviously, this becomes complicated since it is often desired that each page of the sequence appear in order so that each even numbered page appears on the back side of each odd numbered page, as in a book, for example. In addition, further complications are introduced when multiple copies of each page are to be printed.

[0005] An example of a system and method for effecting printing of copies by sets is shown in US-A4,099,254. While the device shown in this patent solves many of the problems heretofore associated with copy generation, it does not provide for job recovery, i.e., recovery from jams occurring with respect to copy sheets, or errors introduced due to double, or lack of, feed of copy sheets.

[0006] Job recovery has been heretofore suggested and used with respect to copying devices, including those capable of printing multiple copies and effecting duplex copying. Such job recovery, however, has not been completely satisfactory, at least for all instances, and particularly with respect to recovery from jams occurring during second side copying of multiple duplex copies.

[0007] Prior art suggestions have included devices with counters and the like for counting documents and/or copy sheets to effect both simplex and duplex copying. However, such devices have not proven to be completely satisfactory and/or capable for use in job recovery for automatic recovery from jams occurring with respect to generation of multiple copies and/or jam recovery during second side copying.

[0008] In addition, heretofore known copying devices and methods have not proven to be completely satisfactory for generation of complete sets of copies when double or lack of copy sheet feeding has occurred, or when interruption of copying has occurred. In addition, while providing for copy counts, such devices and methods have not adequately provided for counts of copies generated without including in such counts any copies generated for replacement purposes.

[0009] This invention seeks to provide an improved method and system for printing complete sets of duplex copies including generation of replacement copies due to jams.

[0010] Accordingly, a system for printing duplex copies, comprising printing means for printing images on copy sheets at a printing area, a storage receptacle for storing copy sheets, a duplex tray and means for causing movement of copy sheets in a copy sheet path from the storage receptacle through the printing area to the duplex tray and from the duplex tray through the printing area to an exit station, is characterised by first sensor means for maintaining a count of copy sheets in duplex tray, second sensor means for maintaining a count of copy sheets received at said exit station, and means, effective upon a jam occurring during normal printing, to determine the copy sheets lost and to cause replacement copies to be printed prior to resumption of normal copy printing.

[0011] A method of printing duplex copies, comprising initially sequentially feeding copy sheets to a printing area for printing on one side of the sheets, storing the sheets in a duplex tray after copying has occurred on one side, sequentially feeding the copy sheets in the duplex tray to the printing area for copying on the other side of the sheets, and then collecting the sheets twice fed through the printing area at an exit station, is characterised by maintaining a count of copy sheets in the duplex tray and a count of copy sheets at the exit station, determining, upon occurrence of a jam during normal printing, at least in part from the counts, copies lost due to the jam, and using the determination of copies lost to generate replacement copies.

[0012] The invention could be defined as a method for generating duplex copies of a plurality of images without loss of copies due to copy material jams occurring during copy generation, comprising sequentially providing to a printing area at least a representation of each image to be printed, providing dual-sided copy material to the printing area with the copy material being capable of having an image printed on each side thereof, causing the image then being represented at the printing area to be printed on a predetermined first side of the copy material, storing the copy material having an image on the first side thereof in a duplex tray, maintaining a count of copy material in the duplex tray; causing the copy material to be withdrawn from the duplex tray and fed to the printing area for printing on the second side thereof of a different image represented at the printing area, moving to an exit station the copy material twice fed to the printing area, maintaining a count of copy material received at the exit station, interrupting copy generation whenever a jam occurs with respect to the copy material, using the counts to determine copied images lost from each side of copy material involved in the jam; representing at the printing area the representation of images determined to have been lost due to the jam to cause new copies thereof to be made, and continuing copy generation after the new copies have been made of lost images.

[0013] Such a method may include placing the new copies in the duplex tray when the new copies are made to replace copies lost due to a jam of the copy material that occurs during the second side copying.

[0014] Such a method may also include providing a count of total pages in a set of images to be copied, dividing the count of total pages by two and then subtracting therefrom the count of copy material in the duplex tray and the count of copy material received at the exit station.

[0015] Where the dual-sided copy material includes a plurality of discrete copy sheets, such a method may also include providing a count of the copy sheets fed to the printing area for determination of completion of each set of copies being generated.

[0016] The invention may alternatively be defined as a method for printing images of both sides of each of a plurality of recording media in response to received electrical signals representative of the images without loss of printed images due to jams occurring with respect to the recording media, comprising providing first and second pluralities of electrical signals representative of first and second groups of images, respectively, presenting the first plurality of electrical signals at a printing area to thereby cause the first group of images to be printed on one side of the recording media, storing the recording media with the images on one side thereof in a duplex tray, maintaining a count of recording media in the duplex tray, presenting the second plurality of electrical signals at the printing area along with the recording media withdrawn from the duplex tray thereby to cause the second group of images to be printed on the other side of the recording media, passing the recording media having been twice presented at the printing area to an exit pocket, maintaining a count of recording media passed to the exit pocket, interrupting printing of images on the other side of recording media when a jam occurs with respect to the recording media, using the counts to determine printed images of both the first and second groups of images lost due to the jam, representing at the printing area the first electrical signals representative of the first group of images determined to have been lost due to the jam thereby to print new images thereof on the recording media, storing the recording media with the newly printed images printed thereon in the duplex tray, representing at the printing area the several electrical signals representative of the second group of images determined to have been lost due to the jam and withdrawing the recording media having the newly printed images thereon from the duplex tray thereby to print new images of the lost images on the other side of the recording media, and thereafter continuing printing of the second group of images.

[0017] Such a method may include determining the total number of images made during printing exclusive of images made to replace images lost due to jams, and using the determination for billing purposes.

[0018] In the latter case, determination of the total number of images made exclusive of images made to replace images lost due to jams may include maintaining a count of the number of images made on each side of the recording media and precluding an increase of the count when printing images to replace lost images.

[0019] The invention extends to a method for billing the total number of images copied by a device for printing duplex copies wherein copy sheets are stored in a duplex tray after printing on one side and moved to an exit station after printing on both sides, and wherein replacement copies are generated to replace copies lost due to jams, double feeds or blank pages, comprising maintaining a count of copy sheets stored in the duplex tray, maintaining a count of copy sheets received at the exit station after being copied on both the first and second sides, determining the number of replacement copies made by the device to replace copies lost due to jams, double feeds or blank pages, and determining from the counts the total number of copies to be billed, the total number of copies to be billed being exclusive of the replacement copies determined to have been made.

[0020] The invention further extends to a system for effecting job recovery in a printing device having a storage receptacle for storing copy sheets, a duplex tray for storing copy sheets with one side having copy thereon, and means establishing a path for the copy sheets from the storage receptacle through a printing area to the duplex tray and from the duplex tray through the printing area to a copy sheet exit station, comprising first means for determining the number of copy sheets withdrawn from the storage receptacle and from the duplex tray, second means for determining the number of copy sheets in the duplex tray, third means for determining the number of copy sheets received at the copy sheet exit station, and means connected with the first, second and third determining means and responsive thereto for causing the printing device to generate replacement copies due to copy sheet losses occurring during a jam.

[0021] The scope of this invention is defined by the appended claims; and how it can be carried into effect is hereinafter particularly described with reference to the accompanying drawings, in which:-

FIGURE 1 is a schematic and block illustration of the sheet feed path in a printer including job recovery means according to the invention; and

FIGURES 2 to 18 are flow charts illustrating the operation of the control for the printer illustrated in Figure 1.

[0022] The invention is described as applied to a printer 21 (Figure 1) such as shown and disclosed in greater detail in US-4,099,254, FR-2366129 and DE-2744323.

[0023] As so disclosed, the printer 21 may be used to form an image (normally visual although nonvisual images could also be formed) on a recording medium (such as a discrete paper sheet, although a continuous web surface could also be utilized). The image is formed in response to an electrical signal representative of the image when the electrical signal representation is presented,at a copying, or printing, area. The recording media, in the form of copy sheets, are transported to the copying area one by one so that the image is formed thereon in the manner disclosed and only those details of the printer as are necessary for an understanding of this invention are described herein.

[0024] Blank copy sheets from a copy sheet tray 31 are transported to a rotating xerographic drum 25 which has thereon the image to be printed. To effect imaging, copy sheets are fed past a transfer station 27 where the images are transferred onto one side of the sheet at the copying, or printing, area. Each sheet printed at transfer station 27 is then transferred along a copy sheet path through a fixing, or fusing, station 29. Thereafter copy sheets are transported either along a path 39 to an exit pocket 43 or along a path 45 to a duplex tray 33.

[0025] Copy sheets with no printing on either side are initially withdrawn from the copy sheet tray 31, whereas copy sheets printed on one side are withdrawn from the duplex tray 33. In each case, the withdrawn copy sheet is fed along a copy sheet path 35 through a synchronizing gate 37 prior to being conveyed to transfer station 27 so that each sheet is fed to the transfer station in synchronism with the movement of the image on drum 25.

[0026] After the image has been fixed on the copy sheet, the path of the copy sheet is controlled by a diversion vane 47. If the copy sheet is transported along path 39, it can be reversed by reversing means 41. Finished copy sheets 23 accumulate in the exit pocket 43.

[0027] A FED sensor 49 is located alongside the path 35 to effect a count of all copy sheets, whether from copy sheet tray 31 or duplex tray 33, fed to the copying area. In addition, an EXIT sensor 51 is located adjacent the exit pocket 43 to effect a count of copy sheets discharged from the copy area along path 39, and hence effectively discharged from the printer. A TRAY sensor 53 is located at the duplex tray 33 to sense the presence of any copy sheet in the duplex tray, and indicates either that the duplex tray is empty or not empty, having at least one copy therein. An additional sensor 55 is located alongside the path 45 to effect a count of all copy sheets fed into the duplex tray 33.

[0028] In conjunction with each of the sensors 49, 51 and 55, a corresponding counter is provided in a processor 57, which processor may be a microprocessor which includes processing for the entire operation of the printer and which controls imaging and copy sheet control unit 59 as disclosed in _US-4,099,254, FR-2,366,129 and DE-2,744,323. The processor also includes an indicator controlled by the sensor 53.

[0029] The function of the processor 57, in accordance with this invention, is for job recovery as described hereinafter. To effect job recovery, the processor 57 also receives information as to the total number of prints imaged for the set then being printed from PRINTINT register 61, information as to the total number of pages for the set from _SIGNUMBR register 63, and information as to the number of sets then made for a particular job from NUMSETS register 65. In addition, the processor 57 is also connected to an INTERRUPT switch 67 for effecting interruption of copying as desired by an operator.

[0030] For printing duplex copies, printer 21 operates generally by writing one page of data at a time in alternating memory files so that page 1 is written on a first file (file 1), page 2 is written on a second file (file 0), page 3 is then written on file 1 immediately next to page 1, and so forth until all pages are written.

[0031] The data are then read back for duplex copy printing purposes by reading the entire first file (file 1) before reading the second file (file 0). For reading of the first file, all of the pointers of the first file are reversed so that the last page (page 9, for example) is read first followed by each immediately adjacent page (pages 7, 5, 3 and then 1, for example) with each copy sheet imaged for the odd numbered pages of file 1, i.e. copy sheets having an image on one side thereof, being transferred to duplex tray 33. In this manner, the copy sheet carrying page 9 is stored at the bottom of duplex tray 33 with the copy sheets carrying pages 7, 5, 3 and then 1 being stacked thereabove.

[0032] After file 1 is read, then file 0 is read in regular, or normal, order as written, that is, pages 2, 4, 6, 8 and then 10, with each of the even numbered pages being printed on copy sheets withdrawn from duplex tray 33. The copy sheets in the duplex tray 33 have their printed faces uppermost and the tray is a Last In First Out (LIFO) storage. Thus, the copy sheet with page 1 printed on one side is first presented to the printing area when withdrawn from duplex tray 33, so that page 2 is printed on the opposite side thereof. In this manner, each copy sheet is imaged on the opposite side and the copy sheets twice exposed at the printing area are then conveyed to exit pocket 43, where a complete set is collected with each copy sheet having an odd numbered page on one side and the immediately following even number page on the opposite side, i.e. the first copy sheet has page 1 on one side and page 2 on the opposite side, the second copy sheet has page 3 on one side and page 4 on the other side, and so on.

[0033] It is arranged that the copy sheets drop into the exit pocket 43 with odd numbered pages face down so the set is already collated. Depending upon the direction of arrival of the copy sheets, this may necessitate the use of the reversing means 41.

[0034] For job recovery for the first set of copies and for the first side of multiple sets, recovery can be effected by simply reprinting the copies lost. Thus, if two copies are lost due to a jam, two replacement copies are generated after clearing the jam, and the printing job can proceed in the normal manner. For job recovery due to lost copies occurring during second side copying of multiple sets of copies, the number of lost copies must first be determined and then replacement copies must be generated with each replacement requiring printing of the first side of each copy sheet before copy generation can be continued in normal fashion with respect to second side printing.

[0035] In this embodiment of the invention, it is not necessary to require the entire set to be remade when a jam occurs during second side printing of duplex copies. To avoid this, a first count is maintained of the total number of pages fed to the printing area, sensed by sensor 49 and counted in the FED counter, for determining when each set to be copied is complete and the next set started; a second count is maintained of the number of copy sheets then in the duplex tray, sensed by sensors 55 and 49 and counted in the TRAY # counter; and a third count is maintained of the number of copy sheets reaching the exit pocket, sensed by sensor 51 and counted in the EXIT # counter. It will be appreciated that the count in TRAY # counter is increased by signals from sensor 55 and decreased by signals from sensor 49 during second side copying. When a jam occurs during side one copying, replacement sheets are generated after the jam is cleared and normal copy generation is continued. When a jam occurs during side two copying of multiple sets, however, a determination is made of sheets lost in the jam by subtracting the count of sheets in the TRAY # counter and in the EXIT # coun er from one-half the total number of pages in the set, then the first sides of pages determined to have been lost are recopied, and those replacement pages placed in the duplex tray, after which the normal printing operation is continued except that those pages that made it to the exit pocket before occurrence of the jam are not reprinted.

[0036] Thus, the number of pages lost in a jam (R) is determined by the formula :

where TP equals total number of pages in the set to be printed, C_T equals the count in the duplex TRAY # counter, and C equals the count in the EXIT counter.

[0037] Assuming, by way of example, that there are ten pages in the set, that one copy sheet (having pages 1 and 2 printed thereon) has reached the exit pocket (so that the count in EXIT # counter equals 1), and that a copy sheet with page 9 printed on one side thereof is in the duplex tray (so that the count in TRAY # counter equals 1), then according to the formula set forth hereinabove R = 10/2 - 1 - 1 = 3.

[0038] Thus, the three copy sheets which should have had pages 3 to 8 printed thereon have been included in the jam (since pages 1 and 2 are printed on the one sheet in the exit pocket and page 9 is on the one sheet in the duplex tray).

[0039] The imaging control unit is then recycled to cause the electrical signals indicative of the pages on file 1 (odd numbered pages) to be presented at the copying area and new or replacement copies are printed for pages 7, 5 and 3.

[0040] These pages are then placed in the duplex tray and the electrical signals indicative of the pages of file 0 (the even number pages) are then again presented to the copying area for reprinting of pages 4, 6 and 8 on the copy sheets withdrawn from the duplex tray, after which normal operation is continued by withdrawing page 9 from the duplex tray and printing page 10 on the reverse side of that copy sheet.

[0041] As can be appreciated from the foregoing, replacement sheets generated to replace copies lost travel along the same path as copy sheets during the normal printing process. Signals from the duplex tray sensor 55 and exit sensor 51 are used to maintain a count of copy images made (sensor 55 senses the number of side one images on.copy sheets arriving at the duplex tray and sensor 51 senses the number of side two images on copy sheets reaching the exit pocket). To avoid rebilling, or double billing, provision must be made to preclude such a count including such replacement sheets, although generation of each sheet requires remaking side one images.

[0042] In addition, double sheet feeds can occur both into and out of the duplex tray. Double feed is corrected by remaking the entire set. Hence, here again, rebilling for pages serving as replacement copies must be precluded. Likewise, precluding a billing for blank pages must be effected for accurate billing information.

[0043] Control of processing for achieving the abovementioned ends can be effected by means of a software program for the processor, which processor is preferably a microprocessor, and may be of the type shown, for example, US-4,086,658, DE-2,743,284, FR-2,366,625 and GB-1,532,609.

[0044] Relevant portions of a program for effecting the foregoing are appended to this description. The flow charts of FIGURES 2 to 18 explain the attached program. In these flow charts, definitions of the terms utilized are as follows:

FED sheet (print) is fed from paper supply into paper path - supply is either primary, alternate, or duplex tray;

SIDE 2 in duplex mode feeding paper from the duplex tray;

TRAY number of sheets in duplex tray;

PRINTINT number of prints imaged for this set;

SIGNUMBR number of pages per set;

NUMSETS number of sets made to this point in time;

EXIT number of sheets in exit tray for this set;

SKIQ1ST # number of pages to skip before beginning to print when doing error recovery

REMAKE # number of pages to remake after skipping SRIP1ST value.

SKIP2ND # number of pages to skip after remaking REMAKE # value.

[0045] When a copy sheet passes the sensor 49 along the paper path 35 it may have come from the copy sheet tray 31 or the duplex tray 33. Accordingly the FED signal initiates, not only an increase in the count in the FED counter but also (FIGURE 2) a decision whether the copier is in duplex mode and the copy sheet comes from the duplex tray. If so, the TRAY number counter is decremented by one when SIDE 2 and duplex copying is being carried out. This is effected in the program steps at addresses 7FD6 to 7FDE, and is necessary to maintain the proper count in the TRAY number counter to enable job recovery as described above.

[0046] The count in the PRINTINT register 61 is incremented (Figure 3) as a print is made by interrupting the character generator in the imaging unit of the printer, as indicated in the program addresses A8CB to A8CD. This initiates a check to determine whether the count in the PRINTINT register equals the count in the SIGNUMBR, thus indicating that the set is completed. If so, the PRINTINT register is reset to zero and the count in the NUMSETS register is increased by one thus bumping the SET count, as indicated in the program addresses A8EA to A912 and A925 to A938.

[0047] To enable charging for copies prepared, billing takes place each time a print is made. At billing time (Figure 4) a determination is made as to whether SIDE 2 is being printed. If so the sheet just billed goes into the exit pocket and the EXIT number counter is increased by one. If not, then the TRAY number counter is increased by one. This is effected by program steps at addresses AC47 to AC54. In either case, when the entire set is indicated to be in the exit pocket, then the EXIT number counter is reset to zero. This is effected by comparing the count in the PRINTINT register with the count in the EXIT number counter, program addresses AC55 to AC80.

[0048] To set up for job recovery due to a jam, (Fig.5) indicated by program address _AD3A, determination is made whether it is a first set being copied (program addresses BBF6 to BBFB) because, for the first set, the pages go into and out of the duplex tray one at a time. If a first set is being copied, it is determined whether there are copies in the duplex tray (program addresses BCOO to BC17), and, if so, a condition is set to flush that print from the duplex tray and the billing inhibit is set because the print being flushed was previously billed. After the duplex tray is empty, the recovery registers are set up so that the count in SKIP1ST # is zero, and those in SKIP2ND # and PRINTINT are each equal to twice the EXIT number count (program steps BC19 to BC20). Then the count in REMAKE # is made equal to half the count in SIGNUMBR less the counts in EXIT and TRAY (program steps 9CBF to 9CD6). The count in NUMSETS is made zero. Set up is then completed by setting the printer for side one printing.

[0049] If the set being made when a jam occurs is not the first set, then all sheets with one side 1 imaged thereon are moved into the duplex tray and all side 2 images are made by withdrawing these sheets from the duplex tray. To set up for this, it is determined whether the NUMSETS register was bumped before the jam and, if so, this register is decremented by one (program addresses BC3E to BC45). The recovery registers are then set up so that the count in SKIP1ST # is equal to that in TRAY #, that in SKIP2ND 4 is equal to twice the EXIT count and that in PRINTINT is equal to twice the EXIT # count plus the TRAY # count (program addresses BC48 to BC54). Then the count in REMAKE # is made equal to half the count in SIGNUMBR less the counts in EXIT # and TRAY # (program addresses 9CBF to 9CD6).

[0050] A determination is made as to whether side 2 copying is being carried out, and, if so, the billing inhibit register is increased by the number of pages lost in the jam (program addresses BC55 to BC5D). It is then determined whether the billing inhibit flag in the printer is set (program addresses BC5E to BC68) and, if not, it is set and the billing inhibit count is decremented by one. Set up is then completed by setting the printer for side one copying.

[0051] With respect to jams occurring during first set copying, all data for the job is spooled to a disk memory before error recovery begins. To effect recovery (Fig.6), the pages are brought into the page buffer (program addresses 9DO_A to 9_D23). It is then determined whether there are pages to be skipped (program addresses 9D29 to 9D30), and, if so, the printer is prevented from printing and the page is then skipped (program addresses 9D40 to 9D4B). This effects skipping of any page that has been determined by the TRAY number counter to be present in the duplex tray already. It is then determined whether the next page is in the page buffer (program addresses 9D4D to 9D51 and, if not, more pages are brought in (program addresses 9D53 to 9D6A). The SKIP1ST # register is decremented by one (program addresses 9D6B to 9D6D). It is then determined whether there are any more pages to skip (program address 9D6E) and, if so, skipping of pages is repeated. When all pages to be skipped have been skipped, the first page in the page buffer is that which needs to be printed to effect job recovery.

[0052] When there is a page in the page buffer that is apparently ready to print to effect job recovery (Fig.7), a determination is made as to whether the REMAKE number equals zero (program addresses 9E35 to 9E41) and the SKIP2ND number is not equal to zero (program addresses 9E21 to 9E34) (indicating that there is a page to be skipped due to duplex error because the page is already in the exit pocket). If so, then the SKIP2ND number register is decremented by one and the page buffer is skipped to the next page. If not, then a determination is made whether the REMAKE number is greater than zero (program addresses 9E35 to 9E39). If the REMAKE number is greater than zero, then it is decremented by one (program addresses 9E45 to 9E47). If it then equals zero, a special side change control is effected to change from side one to side two after this page is placed in the duplex tray (program addresses 9E48 to 9E4E). When the REMAKE # is found to be equal to zero, the program allows the system to print the page, unless SKIP2ND is not equal to zero. After the page is printed, the order will be entered again until all pages to be skipped are skipped and all pages to be printed have been printed.

[0053] When printing of a set of copies is interrupted, it is desired that the job be later continued to complete the job from the same point as where interrupted. In this embodiment a copy interrupt sets up the recovery registers so that the background print job will continue from the point of interruption when the copy job is complete.

[0054] When a copy interrupt occurs, (Fig.8), it is determined whether a first set is being printed, and, if so, the recovery registers are set up as described after a jam during the first set (program addresses B64B to B673). If not, copy interrupt is activated on a set boundary so that there is no special recovery requirement, so that the registers are not altered because they are correct. A copy interrupt can occur on other than a set boundary for second and subsequent printing sets, but only if a jam occurs or is in progress when a copy interrupt is initiated. If so, jam recovery takes over and sets up the registers appropriately, as described above.

[0055] Special error recovery is provided for double feed which may occur at any time either on prints going into the duplex tray or caning out of the duplex tray. A double feed is detected either when during printing out of the duplex tray, the duplex tray becanes empty before canpleting that set (double feed occurring out of duplex tray) or, upon completing the set, there are still sheets in the duplex tray (double feed occurring going into the duplex tray). A double feed causes a deficient set of copies to be generated and the point of deficiency cannot be determined since it can be anywhere in the set. This means that the entire set needs to be remade.

[0056] In such conditions (Figure 9) , it is determined whether there are copies in the duplex tray and, if so, routines NUMSETS and PRECSMAL are called to indicate that, even though the set number was bumped, it is going to be remade and therefore must be decremented (program addresses BOC4 to BODD and BOBF to BOC2).

[0057] Before the printer responds to an instruction to initiate printing (Figure 10), a determination is made as to whether it is side two copying and that copies are not in the duplex tray. If not, the page is printed, but, if so, a flag is set to do recovery later and the page is not printed (program addresses BA7F to BA93).

[0058] If the paper path is clear (Figure 11), it is determined whether the recovery later flag is set, and, if so, PRECSMAL is called (program addresses AE59 to A_E62). When PRACSMAL is called, a recovery subroutine (Figure 12) is initiated and the registers TRAY #, PRINTI_NT, SKIP1S_T #, REMAKE, SKIP2ND and EXIT # are set to zero (program addresses BCB8 to BCCF).

[0059] In billing control, when the pages of side one are made, they are billed. If replacement pages must be made later due to jams, these replacement pages are not to be rebilled. In addition, blank pages are not to be billed, and remake of sets due to double feeds are not to be rebilled.

[0060] For billing control set up, a billing inhibit control is provided in the printer and can be the same mechanism for both copy and print modes. When a copy interrupt occurs, it must reflect the proper inhibit state in the proper mode (print or copy).

[0061] When a copy interrupt occurs (Figure 13), a determination is made as to whether the billing inhibit flag is set, and, if so, the flag is reset and the billing inhibit count is bumped (program addresses BDE5 to BDEC). After a copy is printed (Fig.14), it is determined whether the billing inhibit count is not equal to zero and, if not, the billing inhibit flag is set and the billing inhibit count is decremented (program addresses BBOF to BB1B).

[0062] When a jam occurs (Figure 15), it is determined whether a first set is being copied and, if so, then the billing inhibit flag only is set since only one print was lost (program address BC13). If not a first set, a determination is made whether it is on side two printing, and if so, the number of pages lost in the jam is added to the then prevailing value of the billing inhibit count (program addresses BC55 to BC6A). It is then determined whether the billing inhibit flag is on and, if not, it is set and the billing inhibit count is decremented.

[0063] Any page can be forced blank by an operator, and such pages are not to be billed. At the time a page is printed there may be several other prints in the paper path on their way to the exit pocket. It is important to inhibit billing on the correct pages and not to inhibit billing on an arbitrary page due to potential paper jams and recovery necessary for billing control.

[0064] In the set up for blank page billing control (Fig.16), a determination is made as to whether the page is blank and, if so, the appropriate bit is set in the blank page control byte not to bill the appropriate page (program addresses BA9A to _BAD6). The blank page control byte is a shift register which is shifted each time a sheet is billed with bit zero indicating that the next page is not to be billed. The appropriate bit is set in the shift register relative to when a page is· to be billed.

[0065] For double sheet feeds, the entire set is to be remade and the sides previously billed are not to be rebilled by generation of replacement copies. For set recovery in this condition (Fig.17), the number of prints billed in the set is added to the prevailing value of the billing inhibit count so that the inhibit count is changed by adding thereto P_RINTINT, i.e. the number of sheets to be remade (program addresses BCB8 to BCD8). A determination is made as to whether the billing inhibit flag is reset and, if so, the flag is set and the billing inhibit count is decremented. Thereafter the blank page billing control byte is reset.

[0066] When billing for sheets printed (Fig.18), a determination is made whether the billing inhibit count is greater than zero. If not, a determination is made whether the next page is blank by using the bit zero of. the blank page control byte, and, if so, the billing inhibit flag is set and the blank page control byte is shifted. If the next page is not blank, the billing inhibit flag is reset and the blank page control byte is shifted. If the billing inhibit count is greater than zero, then the billing inhibit count is decremented, the billing inhibit flag is set, and the blank page control byte is shifted (program addresses AC80 to ACA2). The billing inhibit flag set indicates that the next sheet entering the appropriate exit pocket is not to be billed.

[0067] As can be appreciated from the foregoing, this embodiment of the invention provides an improved method and system for job recovery and is particularly well suited for automatically effecting job recovery from jams occurring during second side printing of duplex printing copies as well as providing updated billing information in conjunction therewith.

[0068] For convenience, the embodiment described uses the same technology as the printer to which it is applied. It will be understood, therefore, that the invention could be applied by means of interconnected latch logic control, if, for example, this was used for controlling the operation of the printer.

[0069] The following are the relevant portions of the program referred to above, together with explanations of mnemonics used.

[0070] 

Claims

1 A system for printing duplex copies, comprising printing means (25,27) for printing images on copy sheets at a printing area, a storage receptacle (31) for storing copy sheets, a duplex tray (33) and means for causing movement of copy sheets in a copy sheet path from the storage receptacle through the printing area to the duplex tray and from the duplex tray through the printing area to an exit station (43), characterised by first sensor means (55) for maintaining a count of copy sheets in duplex tray, second sensor means (49) for maintaining a count of copy sheets received at said exit station, and means, effective upon a jam occurring during normal printing, to determine the copy sheets lost and to cause replacement copies to be printed prior to resumption of normal copy printing.

2 A system according to claim 1, including third sensor means for maintaining a count of copy sheets withdrawn from the storage receptacle and from the duplex tray for determining completion of copied sets.

3 A system according to claim 2, including a register for maintaining a count of the number of sets copied.

4 A system according to claim 1, 2 or 3 including a register for maintaining a count of the number of pages per set to be copied.

5 A system according to claim 4, in which the determining means is effective to determine R, replacement copies needed, according to the formula:

where _TP is the total pages in the set to be printed, G_T is the count of pages in the duplex tray, and ^C _E is the count of copy sheets at the exit station.

6 A method of printing duplex copies, comprising initially sequentially feeding copy sheets to a printing area for printing on one side of the sheets, storing the sheets in a duplex tray after copying has occurred on one side, sequentially feeding the copy sheets in the duplex tray to the printing area for copying on the other side of the sheets, and then collecting the sheets twice fed through the printing area at an exit station, characterised by maintaining a count of copy sheets in the duplex tray and a count of copy sheets at the exit station, determining, upon occurrence of a jam during normal printing, at least in part from the counts, copies lost due to the jam, and using the determination of copies lost to generate replacement copies.

7 A method according to claim 6, including providing a count of total pages in each set of material to be copied, and determining copies lost by dividing by two the total number of pages in the set of material and subtracting therefrom the number of copy sheets in the duplex tray and the number of copy sheets at the exit station.

8 A method according to claim 6 or 7, in which the generated replacement copies are placed in the duplex tray prior to continuation of normal copy generation after a jam has occurred during second side copying of the copy sheets.

9 A method according to claim 6, 7 or 8, including maintaining a count of copy sheets fed to the copying area, and using the same to determine completion of copy sets.

10 A method according to claim 6, 7, 8 or 9, including interrupting copy generation for a predetermined job while maintaining necessary count information with regard to the job whereby the job can be completed after termination of the interruption.

11 A method according to claim 6, 7, 8, 9 or 10, including providing for billing purposes a total count of sides of copy sheets exposed for printing at the printing area, by maintaining a count of the copy sheets fed to the duplex tray and a count of the copy sheets received at the exit station.

12 A method according to claim 11, including precluding an increase in the count of sides of copy sheets during generation of the replacement copies.

Drawing